Hydrogenated amorphous silicon (a-Si:H) p–i–n solar cell performance has been optimized using a two-step i-layer growth process. This effort has been guided by real-time spectroscopic ellipsometry (RTSE) studies of the nucleation and growth of a-Si:H films by plasma-enhanced chemical vapor deposition at 200 °C using a variable H2-dilution gas flow ratio R=[H2]/[SiH4]. RTSE studies during film growth with R>15 reveal a transition from the amorphous to microcrystalline (a→μc) phase at a critical thickness that decreases with increasing R. From such results, the optimum two-step process was designed such that the initial stage of the i layer (∼200 Å) is deposited at much higher R than the bulk to ensure that the film remains within the amorphous side of the a→μc phase boundary, yet as close as possible to this boundary at low i-layer thicknesses.
Real time spectroellipsometry (RTSE) has been applied to study the growth of a-Si1-xCx:H alloys (x∼0.1; Eg=1.90–2.00 eV) for applications as i- and p-type layers in wide band gap solar cells. Two important material parameters, the optical gap and the relative bond-packing density (or void volume fraction), can be estimated from RTSE data collected during the growth of a sequence of layers onto the same substrate using different plasma-enhanced CVD conditions. In this way, large regions of parameter space have been scanned expeditiously, and an improved understanding of the effects of H2-dilution, substrate temperature (Ts), plasma power, gas pressure, and gas flow on the film properties has been obtained.
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